1967-1967 Chevy Chevelle A/C Control Panel Fix - Control Issues

Restore Your '66-67 A/C Control Panel

If you own a '66-67 Chevelle with factory A/C, it's no secret that the original heater and A/C control levers are a problem you will have to address sooner or later. We're betting on sooner. The control arms are constructed from pot metal and are notoriously weak; they've been known to give up at the slightest hint of a heavy hand. Of course, none of us would ever be guilty of such an infraction ... it's always the fault of a previous owner, right?

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Although we'll be working on a set of '67 controls here, they are very similar to the '66's with only slight production variances. The procedure for replacing the levers in either year, however, is virtually the same. Like most setups we've seen, our middle arms were the ones "out of control." This is probably due to the fact that they mechanically control, through sliders and cables, the mechanical movement of internal "doors" in the A/C system to accomplish their jobs.

Of course, the problem of a poor design and even poorer materials is compounded by the fact that the cables they actuate are usually corroded and difficult to move as well. So, in order to maintain the function of the controls after you've restored them, we also recommend removing the original cables, lubricating, and "working" them until they slide freely. Or, if they're too damaged, you should consider replacing the control cables at the same time.

Before beginning, you may want to hit the books. That means sticking your nose in the appropriate service and assembly manuals. Doing so will give you an idea of how the components work together, as well as diagrams of how all the parts are assembled.

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We ordered our new control levers from National Parts Depot (NPD), and just to be safe, we popped for some new cables as well. The new levers are fabricated from steel and will function well for many years. The replacement cables, however, differ slightly in appearance but are the correct length and function just like you'd expect new ones to. And while we had NPD's catalog open, we also spec'd a new control panel lens, so everything would look as good as it functioned. With our parts in hand, we were ready to begin the process. Our first step was to disconnect the battery to prevent any possible shorts or other electrical dangers while we're working.

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1967-1967 Chevy Chevelle A/C Control Panel Fix - Control Issues

To ensure proper disassembly techniques and get an idea of how everything fits together, we consulted both the assembly manual and the service manual for our '67 Chevelle.

After removing the two control retaining screws from the bottom of the dash for better access, you can remove the screws holding the control cables to their mounts. Before we did, however, we marked the cables' locations with pieces of numbered masking tape.

Before the control assembly can be removed from the dash, you'll need to remove the plastic distribution ducting that connects to the heating and A/C unit.

Once the control panel is removed from the dash, you can disconnect the wiring from the fan switch. Although ours worked properly, this too, is a commonly failed component. Get a new one if you need to; it's a nonserviceable item.

These little spring washers hold the cables in place on the posts at the end of the levers. You can finesse them off with small needle-nose pliers.

We also used the small needle-nosed pliers to work the knobs off the outside ends of the control levers. Work from behind rather than gripping the knobs, or you can damage the finish.

Once the knobs are out of the way, remove the small, flat, spring clips that retain the metal bezel and clear plastic faceplate.

Now you can drive out the pivot pin that retains the levers, and carefully remove them individually out of the housing. The plastic sliders will exit through openings in the ends of the slider guides.

With everything disassembled, here are the parts we'll be reusing. To maintain originality, we chose to replace only the two arms that were broken, rather than all four. We also cleaned the chrome control knobs and inspected all moving components for wear.

Here's the '67 replacement lever kit and cables from NPD. Even though the '66 version of the A/C control is very similar, it requires an entirely different kit.

The steel replacement levers duplicate the bends, pivot points, and cable attaching posts of the originals. The right-angle stop seen on the original lever, however, is not present on the replacement; evidently it's not needed. The slider extension will have to be transferred from the original as well.

We detached the slider extension from the original lever by drilling and filing down the retaining rivet.

It attaches to the replacement lever with hardware contained in the kit.

To maintain the proper relationships of the levers, the kit also contains nylon spacers of the proper thickness and diameter...

...Once all the levers are in position, secure the pivot pin with the original retaining clip.

Even after lubricating them, the old cables still didn't move as freely as we liked, so we replaced them with new ones. Although they differ slightly from the originals, the fit and function is every bit as good.

After feeding the new cable through the firewall, we reattached it to the inside/outside air control arm on top of the A/C box. Notice the slot on the cable that allows for adjustment and proper opening and closing of the air door.

To add some original detail to our refurbished control panel, we trimmed out the backing plate using a silver paint stick. It's easy and makes a noticeable difference in the final product.

Once the levers were reinstalled, we lubricated all the sliders with lithium grease to ensure no-bind operation...

...Then we placed our detailed backing plate and new faceplate into position, and finally, secured the outer metal bezel with the original, flat retaining springs.

The control cables are reattached to the control assembly using the original, flat, round spring clips and screws that hold them to their mounts. Here's where we were glad we numbered the cables for proper locations.

With everything reconnected, the control panel slides back into place and is retained with the two screws through the bottom of the dash. You can also reinstall the plastic ducting at this point.

Our A/C controls now work and look like new again! Our total time, start to finish, was only a little over two hours. So what are you waiting for?

Muscle cars of yesteryear didn't come with all the creative comforts that are normally included in today's cars. We install a Vintage Air Gen IV Sure Fit Series a/c system into a 1970 Chevrolet Chevelle Malibu. Check it out here at Super Chevy Magazine. » Read More